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The Final Mill Report
The Final Mill Report
KAITHAL
Submission of training report in the partial fulfillment of the requirement for the award of degree of B. Tech
Submitted By:Name: Deepak Sharma Roll no: 1709564 Semester: 5th (Fifth) Session: August 2011 to December 2011
ACKNOWLEDGEMENT
I am Deepak Sharma pre-final year student of MECHANICAL ENGINEERING in HCTM,KAITHAL completed the training from THE KAITHAL CO-OPERATIVE SUGAR MILLS LTD.KAITHAL (HARYANA). Under the guidance of ER. KRISHAN KUMAR SHARMA. Firstly they help me to complete this training on time and also create better study environment that helps me in increasing my design skills. I am also very thankful to Er. ARVIND KUMAR who solved all my queries and satisfy me a lot. He is contact on following address: BLOCK-B SUGAR MILL COLLONY, KAITHAL (HRY). I again very thankful to the authority of the organization regarding my training.
ABSTRACT
Industrial training is part and parcel of our technical course and give a face or form to all the theoretical knowledge we gain in our classroom. We get to have a virtual experience of the processes methods, objects and phenomenon which used to be just a imaginary picture in our mind. It also give an explosure to the environment of the industry and workshop which are virtual component of our professional life. We too were get this opportunity this summer. K.C.S.M.(Kaithal cooperative sugar mill) offers a wide range of machine, mechanism and devices, in the industry we get face to face with the life of a mechanical engineer. This industry established in 1991, located at 4 k.m. away from the city kaithal. There was a lot of useful machines like boiler, turbines, feed pump, pan, quads, etc. Today sugar mill kaithal is one of the best mill in Haryana. The workers working in this mill is nearly 750 which are giving there best for the future of the company. The production of the mill is 2500 tonn . This mill provides there sugar to different parts or states of india and it is a proud for us that we have got trained from this national working company.
TABLE OF CONTENTS
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 10.1 10.2 11. 12. 13. 13.1 13.2 13.3 13.4 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Description of contents
Factory profile Plant layout Flow chart Cane unloader Cane carrier Cane leveller Cane cutter Cane fibirizor Mill house Mixed Juice tank Juice tank Juice sulphation tank Callifier Vaccum filter Evaporator and boiling plant 1st evaporator body 2nd evaporator body 3rd evaporator body 4th evaporator body Vapour cell Syrup sulpation tank Pen station Crystallisor Hopper Sugar gradder and bagging Baggase carrier with elevator Mollasses storage tank Boiler Turbine Conclusion
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TABLE OF FIGURES
S. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cane Unloader Cane Carrier Cane Leveller Cane Fibrizor Mill House Calirifier Vaccum Filter Semi Kessioner Evaporator Body Syrup Sulphiter Tank Pen Station Boiler
Description
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1. FACTORY PROFILE
The sugar mill is established in 1991.
Location -4km away the city kaithal Raw material sugar cane Product- sugar Turn over-40 crores(2009-2010) Production-With 2500TCD production of 2500quintal(app) takes place
No. of workers-750(app)
3. FLOW CHART
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Cane Cane yard Cane Carrier Leveller Cutter Fibrizor ( Quartary Ammonium Compound + Dia Thio Carbonate Base ) II Mill III Mill iV Mill Boiler Mixed Juice Steam ( Phosphoric Acid ) Turbine Mixed Juice Tank Bagasse Ist Mill
Juice Heater (Ist heating Raw juice 70c) House Juice Sulphitor Juice Heater ( IInd Heating sulphited juice 102c ) ( Magna Floc LT 27 ) Vaccum filter Mud Clear Juice Clear juice heater (116C) Mixed Juice Tank Semi Kessioner Vapour Cell Ist Body Evaporator Anti Scalent + Caustic Soda + Cmmon salt + Scale
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Clarifier
Muddy
juice
Filtrate Juice Go to
II Body Evaporator
III Body Evaporator Softner (chemical Boiling .) Iv Body Evaporator Cleaning of evaporator bodies. Syrup Syrup Sulphitor SO2 gas Syrup Tank Seed Slurry +Phosphoric Acid + Hydrosulphite soda + Phosphoric Acid Massecuite Crystallizer Molasses Tank Molasses Centrifugal Machine Moist Sugar Hopper I Hopper II Hopper III
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Pan Station
4. CANE UNLOADER
FIG 1(CANE UNLOADER) i. The function of can eunloader is to pick up the cane from the tractor and sterred into the cane carrier chain
ii. Capacity is 5T,long travel speed is 15m/min by means of electric motor
5. CANE CARRIER
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The function of this chain is to carry the cane which is dropped by the unloader Its horizontal length is 32.119m and width is 1700mm,feeding depth is1600mm Its total length is 51.41m It is driven by electric motor HP50 and rpm 1440
6. CANE LEVELLER
The function of cane leveller is to smooth running of the cane because the cane dropped by the unloader is not in proper manner.
No. of blades used are 32. Motor driven by 250HP and at 589 rpm. Clearance between carrier and blades 180 mm.
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7 . CANE CUTTER
Its function is to make small pieces of sugar cane by means of knives which are dragged on the roller
No. of blades is 36 Motor driven 250HP Material of the blade is mild steel
8. CANE FIBRIZOR
It used to make the fibres of all small pieces of canes which are forwarded by cutter.
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It has 64 hammer of stainless steel having cast steel body. They are in the rectangular shape. This is also driven by electric motor.
9. MILL HOUSE
The function of mill house is to drawn the juice from the fibre of the cane received by the cane carrier chain. There are 4 mill in the plant.
1st mills job is to drawn the juice approx. 70% juice are drawn here with the help of
These 4 rollers are driven by steam turbine with the help of primary gear, secondary and the transmission gear.
All the juice driven by the roller is to be collected in the juice tank with the help of pumps. Pitch : 50 mm
Feed : 65mm Grooves : 34mm
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Depth: 46mm
Feed : 33mm Grooves: 56mm Depth 30mm RPM of turbine 3000-4000 Control by Governor In this mill complete juice is drawn out from the cane and residue is called Baggasse, which is carried by Baggasse carrier chain.
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Effective width 1500 mm The Electric motor haspower 37 kilowatt at 1470 RPM The RED. GEARBOX ratio is 40:1
exhaust and vapour.all five heaters are interchangable and are used for raw and sulphiated juice heating.
Temp. of juice is 70c. Stainless-steel tube outer dia. 45mm (OD)X42mm (ID)x4000mm(L) No. of tubes are 320
After heating the raw juice,it pumped to sulphitation tank. Here juice is mixed with soda-lime and the sulphar gas is passed through the juice.all these things are rotated in a tank with the help of motor at the top of the tank.
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11. CLARIFIER
From the juice heater,juice is pumped to the clarifier,here juice is keep stationary for a sufficent time,so that impurity are setteled down in the bottom. Impurity + some juice is taken out from the tank and pumped to the vacum filter.
Clear juice is pumped again to clear juice heater and here temp. of juice is 116c
FIG 6(CALIRIFIER)
The mud is stick to the screen and the clear juice is passed through the small pipe and finally mixed in juice tank.
2 rotatry vacum filter Dia. 2.44m Length is 4.88m Filtering area 36 sq.m, stainless-steel screen.
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The function of semi kesner is to heat the juice for less than 2 min. It has two chamber Heating surface area is 800 sq.m. Long tube of 45mm (OD) x42mm (ID)x4655mm(L). No. of tubes are 1302.
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Length: 4000mm Heating surface : 450sqm Vapour pipe dia: 600mm No. of tubes: 1724 Tube length: 2 meter
ID : 42.5mm
OD: 45mm
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Vapour pipe dia: 550mm No. of tubes: 1138 Tube length: 2 meter
ID : 42.5mm
OD: 45mm
Length: 4000mm Heating surface : 300sqm Vapour pipe dia: 750mm No. of tubes: 1138 Tube length: 2 meter ID : 42.5mm OD: 45mm
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From storage tank, syrup is pumped to the vacum pan to convert them in solid form. No. of vacum pan: 5 Capacity of vacum pan: 60 tones each Heating surface : 300 sqm Tube length : 900mm No. of tubes : 1094 Syrup change in solid form and it checked time to time by a long checking key provided min tank.
17. CRYSTALLISOR
From the pan, the crystal formed goes to the crystallizer.
3 u-shaped air cooled cryst. Of tonnes capacity each for a m/c 3 v shaped betch type water cooled cryst. ( moving coil) of 65 tones capacity for m/c 2 v shaped air cooled coil cryst. Of 65 tones capacity each for c m/c 25
18. HOPPER
FROM THE CENTRIFUGAL m/c, moist sugar goes to the hopper or sugar drier. There are three gram hopper are single tray and two multi tray gram hoppers. Sugar hoppers no. 2 and 3 with drgint arrangement hot and cold air by blower. Width 1 Width 2 Width 3 Length 1 Length 2 Length 31.5mm (single tray) 1.5mm ( multi tray) 1.5mm ( multi tray) 12m (single tray) 12m (multi tray) 12m (multi tray)
FIG 12(HOPPER)
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Rake type of bagase elevator Length horizontal- 12 meter Inclined length 20 meter Effective width 1500 mm Electric motor drives at 30kw and RPM 1470 Its speed is 25meters/minute
BAGGASE CARRIER
The function of this carrier is to carry the bagasse from the 4th mill
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Horizontal length 8.550 meter Inclined length 26.728 meter Effective width- 1500mm Motor runs at 30 kw and 1465 RPM Reduction Gear Ratio of motor is 40:1 Linear speed- 25m/minute
22. BOILER
The function of boiler is to give the heat to water and then converted into steam. Two no. of bent type bagasse fixed boiler water tube boiler. Working pressure 32kg/sq.cm Heating surface 1170sq.cm Each boiler steam generating capacity 32 tones per hour Efficiency of boiler - 80-85%
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FIG 13(BOILER)
Super heater
The function of this is to heat the feed water by the means of flue gares. Efficiency is improved up to 2% Gilled tube type heating surface 180sq.meter , feed water heating by exhaust steam
Economizer
The function of this is to heat the feed water by the means of flue gares. Efficiency is improved up to 2% Gilled tube type heating surface 180sq.meter , feed water heating by exhaust steam
Purpose for which used for light Power factor No. of phase 0.8 3
Frequency cycle - 50 cycle Maximum demand in season 2500kw Maximum demand in off season 800kw
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CONCLUSION
Training is really important for an engineer. It enhances our confidence. During the training we see the implementation of knowledge that we have gained. It gives us a good exposure to the functioning of organizations. My topic for the training was on production of sugar. I also studied the resources necessary to start any organization. Our mentor Er. Krishan Kumar Sharma stressed on improving communication skills as it plays a very vital role in the corporate world. Three things contribute to communication skills are as under:Body Language Eye Contact Verbal Skill An exposure in the form of summer training is vital before entering into the actual professional career. Thus this training has given me an insight into the industrial world in mechanical field which will prove very helpful in my future professional life.
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